Fiber-reinforced impact-dissipating liners and methods for fabricating fiber-reinforced impact-dissipating liners

ABSTRACT

Impact-dissipating liners, helmets having an impact-dissipating liner, and methods of fabricating impact-dissipating liners are provided. The liners include a fluid impermeable enclosure having cavities with sidewalls, re-enforcing fabric sheets, and a fluid contained in the enclosure. The enclosure may have a central portion and lobes extending from the central portion, wherein the central portion and the lobes are adapted to conform to the shape of an internal surface of a helmet. The re-enforcing sheets may be made from a broad range of materials and may enhance the structural support, structural integrity, and/or durability to the liner. Aspects of the invention are particularly adapted for use as head protection, such as, helmets; however, aspects of the invention are also adaptable to provide impact-dissipation for any body or surface that would benefit from such protection.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to pending U.S. Provisional Patent Application 62/742,869, filed on Oct. 8, 2018, and to pending U.S. Provisional Patent Application 62/893,647, filed on Aug. 29, 2019. This application is also related to co-pending U.S. patent application Ser. No. 15/833,747, filed on Dec. 6, 2017, now U.S. Ser. No. ______. The disclosures of these applications are included by reference herein in their entirety.

BACKGROUND OF THE INVENTION Technical Field

Aspects of the present invention relate generally to protective barriers and headgear, such as, helmets. More particularly, aspects of the invention, in its several embodiments, provide protective, fluid-containing, impact-dissipating liners having reinforcing fabric that enhances the strength and durability of the liners.

Description of Related Art

Numerous human activities, such as, recreation and sports, public protection, and armed service, expose the human body, especially, the head, to impact and injury.

Head injury can be the most traumatic type of bodily injury. Especially when in motion, the exposure of the human head to contact and injury can be a continuous concern, whether the motion is while in a motorized vehicle or on a bicycle. Many attempts have been made in the art of head protection to minimize damage to the skull, brain, and brain stem due to head impact.

Many prior art attempts to address this concern have yielded various helmet designs that provide impact energy absorbing materials, for example, foam rubbers and plastics, in an attempt to provide as much “cushioning” material between the surface of impact and the head. Accordingly, in the state of the helmet art in the early 21^(st) century, it is typical to provide as much foam cushioning within a helmet without detracting from the aesthetic appearance of the helmet. The resulting helmets have been limited in their success in meeting either goals of head protection or aesthetics.

Among other things, as the amount of cushioning material, for example, plastic foam, increases, the larger the envelope and the greater the exposure of the resulting helmet. Specifically, though a larger volume of cushioning material within a helmet may absorb more impact energy, and lessen the amount of impact energy transmitted to the head, the larger volume also increases the torsional movement arm between the point of contact and, for example, the neck, brain stem, and spinal cord of the helmet wearer. Accordingly, providing impact protection while minimizing torsional loading on the wearer is desirable.

Though of relatively minor consequence to some users, the larger the amount of cushioning material typically also results in a more unsightly appearance of the resulting helmet to the typical helmet wearer. Accordingly, there is a need in the art to ensure proper head protection, while, it is preferred, providing an aesthetically appealing helmet.

Though many forms of activity can expose the head to impact loading, athletic completion or contact sports can be one of the more acute concerns for helmet design and head protection. It is well recognized that the repeated contact of the head in such contact sports as football, hockey, and soccer expose the athlete, even though protected with some form of head gear, to degenerative brain damage. The occurrence of chronic traumatic encephalopathy (CTE) in professional athletes, especially in former professional football and hockey players, is well documented. It is generally believed that the repeated exposure of the head to impact loading, even when protected, can result in deteriorating and life changing effects upon cognitive abilities and behavior. Efforts continue to be made to investigate the cause of CTE and to mitigate or prevent its occurrence. Accordingly, there is need in the art to provide more protective headgear for athletes and others.

In addition to head protection, many other bodily, structural, or ornamental surfaces can be exposed to damage due to damaging contact and/or impact loading. Enhancements in, for example, body armor or padding, for bodily protection during military activity, construction, or personal protection, among other activities, continue to be needed. The protection of general walls, barriers, and other surfaces from damage is also desirable.

U.S. Pat. No. 8,856,972 of Kirshon first introduced the concept of liquid-filled, fluid-displaced liner technology to the art. This technology is marketed by KIRSH Helmets of Schenectady, N.Y. under the trademarks Fluid Displacement Liner™ technology or FDL™ technology. Though the inventions disclosed in the '972 patent provide an effective means for dissipating impact loading, further improvements and advantages are provided by the present inventions.

Aspects of the present invention provide protective impact-dissipating liners, for example, headgear, methods of minimizing the transfer of impact loads upon a surface, such as a human body, and methods of fabricating such impact-dissipating liners.

SUMMARY OF THE INVENTION

Aspects of the present invention provide improved impact-dissipating liners that can be used wherever dissipation of impact loading is desirable. Though aspects of the invention may be particularly adapted to protecting humans and animals, for example, in helmets, head gear, body armor, body padding, kneepads, shoulder pads, and shin guards, among others, aspects of the invention may also be employed wherever the protection of surfaces prone to impact would benefit from impact-dissipating protection, for example, race track barriers, stadium walls, and arena surfaces.

Aspects of the invention provide impact dissipating liners and methods of fabricating impact dissipating liners having a flexible, fluid impermeable enclosure, a plurality of cavities extending through the enclosure, a fluid contained in the enclosure; and a fabric sheet positioned in the liner to, for example, provide enhanced structural support, structural integrity and/or durability to the liner.

One embodiment of the invention is a method of fabricating an impact-dissipating liner, the method comprising or including: providing a first mold adapted to receive a first curable fluid, the first mold having a surface, a plurality of projections from the surface, and a plurality of recesses, each of the plurality of recesses about one of the plurality of projections; introducing the first curable fluid to the first mold to at least partially fill the first mold, including at least partially filing each of the plurality of recesses; allowing the first curable fluid to cure in each of the plurality of recesses and on at least a portion of the surface of the first mold to produce an at least partially cured first liner portion; removing the at least partially cured first liner portion from the first mold, the at least partially cured first liner portion having a flexible sheet and a plurality of projections from the flexible sheet; providing a second mold adapted to receive a second curable fluid, the second mold having a surface and a plurality of projections from the surface; introducing a fabric sheet onto at least a portion of the surface of the second mold, the fabric sheet having holes, each of the holes positioned and sized to receive one of the projections from the surface of the second mold; introducing the second curable fluid to the second mold to at least partially fill the second mold and at least partially cover the fabric sheet in the second mold; while the second curable fluid in the second mold is at least partially uncured, introducing the at least partially cured first liner portion to the second mold wherein distal ends of the a plurality of projections of the at least partially cured first liner portion contact the at least partially uncured second curable fluid in the second mold; and allowing the second curable fluid to cure to form a second flexible sheet adhered to the distal ends of the plurality of projections of the at least partially cured first liner portion and forming a fluid-impermeable enclosure; and introducing a fluid to the fluid-impermeable enclosure to provide the impact-dissipating liner.

In one aspect, the fabric sheet may be a woven fabric, unwoven fabric, or a knitted fabric. For example, the fabric sheet may be a knitted fabric comprising a polyethylene terephthalate (PET), a polyester, and an aramid polymer.

In another aspect, the method may include sealing the peripheral edges of the at least partially cured first liner portion with the peripheral edges of the second flexible sheet of the second curable fluid. This sealing process may be practiced while allowing the second curable fluid to cure.

In one aspect, the first curable fluid may be substantially the same as the second curable fluid, for example, a liquid silicone rubber.

Another embodiment of the invention is an impact dissipating liner, for example, a liner for a helmet. The liner may comprise or include: a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and a sidewall extending between the upper wall and the lower wall; a fabric sheet positioned in at least one of the upper wall and the lower wall; and a fluid contained in the enclosure. In one aspect, the liner may include a plurality of cavities extending between the upper wall and the lower wall, each of the plurality of cavities having a cavity sidewall extending from the upper wall to the lower wall.

In one aspect, the fabric sheet in the liner may be a woven, unwoven fabric, or a knitted fabric. For example, in one aspect, the fabric sheet may be a knitted combination of polyethylene terephthalate (PET), a polyester, and an aramid polymer.

In one aspect, the liner may be a helmet liner, and the flexible, fluid impermeable enclosure may be a central portion and a plurality of lobes extending from the central portion, and wherein the central portion and the plurality of lobes are adapted to conform to the shape of an internal surface of a helmet.

In one aspect, the fluid in the enclosure may be a liquid, such as, a liquid silicone rubber, a polydimethylsiloxane, or a polyol.

Another embodiment of the invention comprises or includes a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and a sidewall extending between the upper wall and the lower wall; and a fabric sheet positioned in at least one of the upper wall and the lower wall. The fabric sheet may be a woven, unwoven fabric, or and a knitted fabric. For example, the fabric sheet may be a knitted fabric made from polyethylene terephthalate (PET), a polyester, or an aramid polymer. In one aspect, the liner may include a plurality of cavities between the upper wall and the lower wall, each of the plurality of cavities having a cavity sidewall extending from the upper wall to the lower wall; a fluid contained in the enclosure.

In one aspect, the liner may be a helmet liner, and wherein the flexible, fluid impermeable enclosure comprises a central portion and a plurality of lobes extending from the central portion, and wherein the central portion and the plurality of lobes are adapted to conform to the shape of an internal surface of a helmet. The plurality of lobes may define radially extending cavities between adjacent lobes.

In one aspect, the fluid in the liner may be a liquid, for example, a liquid silicone rubber, a polydimethylsiloxane, or a polyol.

Another embodiment of the invention is a method for fabricating an impact dissipating liner. The method may comprise or include: providing a first mold adapted to receive a first curable fluid, the first mold having mold cavity have a lower surface, a plurality of projections from the lower surface, and at least one recess in the lower surface; introducing the first curable fluid and a fabric sheet to the at least one recess in the lower surface to at least partially fill the at least one recess in the lower surface with the first curable fluid; introducing a second curable fluid to the first mold to at least partially cover the lower surface with the second curable fluid; allowing the first curable fluid to cure in the at least one recess and the second curable fluid to cure on the lower surface to produce an at least partially cured first liner portion; mating the first liner portion with a second liner portion to form a fluid-impermeable enclosure; and introducing a fluid to the fluid-impermeable enclosure to provide the impact-dissipating liner. In one aspect, introducing the first curable fluid and the fabric sheet to the at least one recess comprises sequentially first introducing the first curable fluid to the at least one recess, and second introducing the fabric sheet to the at least one recess.

In one aspect, the fabric sheet introduced may be a woven fabric, an unwoven fabric, or a knitted fabric, such as, a polyethylene terephthalate (PET), polyester, or an aramid polymer.

In one aspect, introducing the fluid to the fluid-impermeable enclosure may be practiced by injecting the fluid into the fluid-permeable enclosure.

In one aspect, the mating the first liner portion with the second liner portion may comprise or include fabricating the second liner portion by a method comprising: providing a second mold adapted to receive a third curable fluid, the second mold having a surface and a plurality of cylindrical recesses in the surface; introducing the third curable fluid to the second mold to at least partially fill the first mold, including at least partially filing each of the plurality of recesses; allowing the first curable fluid to cure in each of the plurality of recesses and on at least a portion of the surface of the first mold to produce an at least partially cured second liner portion; and removing the at least partially cured second liner portion from the second mold, the at least partially cured second liner portion having a flexible sheet and a plurality of projections from the flexible sheet.

A further aspect of the invention is an impact dissipating helmet liner comprising or including a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and a sidewall extending between the upper wall and the lower wall; a fluid contained in the enclosure; and a fabric sheet positioned in at least one of the upper wall and the lower wall. In one aspect, the fabric sheet positioned in at least one of the upper wall and the lower wall comprises a plurality of fabric sheets positioned in one of the upper wall and the lower wall. In one aspect, the liner may include a plurality of cavities between the upper wall and the lower wall, each of the plurality of cavities having a cavity sidewall extending from the upper wall to the lower wall.

A still further embodiment of the invention is a helmet having the impact-dissipating helmet recited herein. The helmet may include a helmet shell adapted to retain the impact dissipating helmet liner.

According to aspects of the invention, impact dissipating liners and method of fabrication impact dissipating liners are provided and the liners can be used to line baseball catcher's helmet, a baseball batter's helmet, a soft ball catcher's helmet, a softball batter's helmet, a hockey helmet, a hockey goalie mask, a motorcycle helmet, a motor cross helmet, a skiing helmet, a snowboarding helmet, a skateboarding helmet, a lacrosse helmet, a bicycle helmet, a jockey helmet, an official's helmet, a medical protection helmet, a rock or ice climbing helmet, a mountain climbing helmet, a football helmet, a construction helmet, and a military helmet, among others.

These and other aspects, features, and advantages of this invention will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention will be readily understood from the following detailed description of aspects of the invention taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of an impact-dissipating liner according to one aspect of the invention.

FIG. 2 is a cross-sectional view of the liner shown in FIG. 1 as viewed along section lines 2-2 in FIG. 1.

FIG. 3 is a cross-sectional view of the liner shown in FIG. 1 as viewed along section lines 3-3 in FIG. 1.

FIG. 4 is a detailed view of the liner shown in FIG. 3 identified as Detail 4 in FIG. 3.

FIG. 5 is a perspective view of a mold for fabricating a portion of the impact-dissipating liner shown in FIG. 1 according to one aspect of the invention.

FIG. 6 is a perspective view of an at least partially cured portion of an impact-dissipating liner produced from the mold shown in FIG. 5 according to one aspect of the invention.

FIG. 7 is a perspective view of a mold for fabricating another portion of the impact-dissipating liner shown in FIG. 1 according to an aspect of the invention.

FIG. 8 is a top plan view of the mold shown in FIG. 7 having a curable fluid.

FIG. 9 is a cross-sectional view of the mold and curable fluid shown in FIG. 8 as viewed along section lines 9-9 in FIG. 8.

FIG. 10 is a cross-sectional view of the liner portion shown in FIG. 6 and the mold shown in FIGS. 7 through 9 prior to engagement according to an aspect of the invention.

FIG. 11 is a cross-sectional view of the liner portion and mold shown in FIG. 10 after engagement according to another aspect of the invention.

FIG. 12 is a top plan view of another mold, having a curable fluid, for fabricating a portion of a liner according to another aspect of the invention.

FIG. 13 is a perspective view of the mold and curable fluid shown in FIG. 12.

FIG. 14 is a perspective view of a portion of a liner fabricated with the mold shown in FIG. 13.

FIG. 15 is a detailed perspective view of a portion of the portion of the liner shown in FIG. 14.

FIG. 16 is a top plan view of another mold, having a curable fluid, for fabricating another portion of a liner according to another aspect of the invention.

FIG. 17 is a detailed perspective view of the mold shown in FIG. 16.

FIG. 18 is a top plan view of the mold and curable fluid shown in FIGS. 16 and 17 having a fabric according to an aspect of the invention.

FIG. 19 is a perspective view of the mold and curable fluid shown in FIG. 18 having a fabric according to an aspect of the invention.

FIGS. 20, 21, and 22 are perspective views of the mold, curable fluid, and fabric shown in FIG. 19 while curable fluid is being introduced according to aspects of the invention.

FIG. 23 is a perspective view of an impact-dissipating liner produced by mating the liner portion shown in FIGS. 14 and 15 with the liner portions produced by the molds, curable fluid, and fabric shown in FIGS. 16 through 22 according to an aspect of the present invention.

FIG. 24 is a perspective view of another impact-dissipating liner produced by mating the liner portion shown in FIGS. 14 and 15 with the liner portions produced by the molds, curable fluid, and fabric shown in FIGS. 16 through 22 according to an aspect of the present invention.

FIG. 25 is a perspective view of a portion of the liner shown in FIG. 24.

FIG. 26 is a detailed perspective view of a portion of the liner shown in FIG. 25.

FIG. 27 is a detailed top perspective view of a portion of the liner shown in FIG. 25.

FIG. 28 is a perspective view of a human head form having a helmet, shown partially in cross section, including a fluid-filed liner with regions having reinforcement elements according to another aspect of the invention.

FIG. 29 is a perspective view, similar to FIG. 28, of a human head form showing the fluid-filed liner shown in FIG. 28, having a helmet with the helmet shell removed to disclose aspects of the invention.

FIG. 30 is a perspective view of the fluid-filled liner shown in FIGS. 28 and 29.

FIG. 31 is a top plan view of the fluid-filled liner shown in FIG. 30.

FIG. 32 is a right-side elevation view of the fluid-filled liner shown in FIG. 31, the left-side elevation view being a mirror image thereof.

FIG. 33 is a cross sectional view of a portion of the fluid-filled liner shown in FIG. 30 as viewed through the section lines 33-33 shown in FIG. 31.

FIG. 34 is a top perspective view of a mold that can be used to fabricate a portion of a fluid-filled liner according to one aspect of the invention.

FIG. 35 is a top view of detail of the mold shown in FIG. 34 as identified by Detail 35 in FIG. 34.

FIG. 36 is a top plan view of reinforcement elements that may be used according to aspects of the invention.

FIG. 37 is a top detailed view of one reinforcement element shown in FIG. 36.

FIG. 38 is a top perspective view of the mold shown in FIG. 34 having cavities at least partially filled with a curable fluid according to one aspect of the invention.

FIG. 39 is a top perspective view of the mold shown in FIG. 38 having cavities at least partially filled with a curable fluid and two of the reinforcement elements shown in FIG. 36 according to one aspect of the invention.

FIG. 40 is a top perspective view of a portion of liner having reinforcement elements after curing of the curable fluid and removal from the mold shown in FIG. 39 according to one aspect of the invention.

FIG. 41 is a perspective view of a portion of the liner shown in FIG. 40 showing a detail of a reinforced region having a reinforcement element according to one aspect of the invention.

FIG. 42 is a top perspective view of a fluid-filed liner fabricated from the liner portion shown in FIG. 40 after mating with a second portion and filling with a fluid according to an aspect of the invention.

FIG. 43 is a bottom view of a helmet having the fluid-filled liner shown in FIG. 42 according to one aspect of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a perspective view of an impact-dissipating liner 10 according to one aspect of the invention. A shown in FIG. 1, in one aspect, liner 10 may comprise a flexible, fluid impermeable enclosure 11 having an upper sheet or wall 12, a lower sheet or wall 14, a plurality of hollow projections 16 extending between upper sheet 12 and lower sheet 14, and sidewalls 18 about the perimeter of upper sheet 12 and lower sheet 14 and extending between the upper sheet 12 and the lower sheet 14. The hollow projections 16 may define hollow cavities 17, for example, open or closed hollow cavities. The cavities 17 may each include cavity sidewalls that extend from the upper sheet 12 to the lower sheet 14.

According to aspects of the invention, at least one of sheets 12 and 14 includes one or more layers 20 of fabric, for example, reinforcing fabric, that, according to aspects of the invention, can provide enhanced strength and durability to liner 10 such that liner 10 can provide enhanced protection, for example, enhanced impact resistance or dissipation, to a surface adjoining liner 10. A portion of fabric 20 is shown in a cut-away section of upper sheet 12 in FIG. 1.

FIG. 2 is a cross-sectional view of liner 10 shown in FIG. 1 as viewed along section lines 2-2 in FIG. 1. FIG. 3 is a cross-sectional view of liner 10 shown in FIG. 1 as viewed along section lines 3-3 in FIG. 1. FIG. 4 is a detailed view of liner 10 shown in FIG. 3 identified as Detail 4 in FIG. 3.

According to aspects of the invention, sheets 12 and 14, projections 16 and sidewalls 18 define an enclosed, substantially fluid-tight cavity 22, and a fluid 24 is introduced to cavity 22 to provide an impact dissipating liner. The fluid 24 may be introduced to cavity 22 by conventional means, for example, by injection, for instance, via a syringe 26, as shown in FIG. 1.

According to aspects of the invention, the fluid 24 in internal cavity 22 and the elasticity of sheets 12 and 14, projections 16, and sidewalls 18 provide a unique energy dissipating function that minimizes or reduces the loading transmitted on, for example, upper sheet 12 to lower sheet 14. This energy or impact-dissipating characteristic of liner 10 can provide an effective device for dissipating the transfer of energy and/or loading upon a surface by providing hollow, possibly gas-filled (for example, air-filled) cavities 17 in projections 16. It is understood that the one or more fabric layers 20 in sheets 12 and/or 14 enhance the durability and strength, if not the impact-dissipating characteristic, of liner 10.

FIG. 5 is a perspective view of a mold 30 for fabricating a portion of the impact-dissipating liner 10 shown in FIGS. 1 through 4 according to one aspect of the invention. As shown in FIG. 5, according to aspects of the invention, a curable or hardenable fluid 32, for example, a liquid silicone rubber (LSR), is introduced to mold 30, and the curable fluid 32 is then allowed to cure, that is, solidify or harden, to form a portion of the impact-dissipating liner 10. As will be discussed further below, according to aspects of the invention, the portion of the impact-dissipating liner formed in mold 30 can then be mated with another portion of the impact-dissipating liner to fabricate the substantially complete liner 10, which, for example, can then be filled with a fluid, for example, a liquid.

According to aspects of the invention, the curable or hardenable fluid 32 may comprise any liquid or fluid that can be introduced to mold 30, or any mold disclosed herein, and then, with appropriate time and/or treatment, will cure or at least partially harden to form a relatively firm structure, for example, a structure that can subsequently be moved, manipulated, and/or otherwise handled as a single, integral component, as disclosed herein, while substantially retaining its molded shape. For example, the curable fluid 32, and any liner or liner enclosure disclosed herein, may comprise a fluid polymer that, upon appropriate treatment, hardens, for example, by cross-linking polymer chains. The curing may be may be effected by time, temperature, chemical additives, and/or radiation, for example, an electron beam or ultraviolet radiation. Curable fluid 32, and the any liner or liner portions formed from curable fluid 32 disclosed herein, may comprise an elastomeric material, for example, a natural or synthetic rubber, a foam, a thermoplastic elastomer, a polyurethane elastomer, a silicone elastomer, a polyvinyl chloride (PVC) elastomer, an olefinic elastomer, a polyamide elastomer, or a gelatinous elastomers, among others. In one aspect, curable fluid 32 may be a silicone, for example, a liquid silicone rubber (LSR), or its equivalent.

In one aspect, the curable or hardenable fluid 32, and any curable or hardenable fluid disclosed herein, may comprise a “medical grade” LSR, as known in the art. In one aspect, enclosure 12 of liner 10 may comprise a liquid silicone rubber marketed by CHT USA (formerly Quantum Silicones (QSi)) under the trademark True Skin® or its equivalent; however, enclosure 12 may comprises any liquid silicone rubber (LSR).

In FIG. 5, curable or hardenable fluid 32 is shown to be representatively poured on to mold 30 from a container 34; however, according to aspects of the invention, fluid 32 may be introduced to mold 30 by any conventional means. For example, fluid 32 may be introduced to mold 30 by injection, by gravity feed, by one or more nozzles, and/or through one or more valves, among other methods. In one aspect, fluid 32 may be introduced by pouring from one or more containers 34.

As shown in FIG. 5, mold 30 may include a surface 36, and surface 36 includes a number of recesses 38, for example, a “plurality” of recesses, distributed about surface 36, for example, uniformly distributed, and into which curable fluid 32 flows and substantially fills each recess 38 with curable fluid 32. Though nine representative recessives 38 are shown in FIG. 5, aspects of the invention may have as few as 1 recess to tens, hundreds, or even thousands of recesses 38, for example, depending upon the application of the aspect of the invention.

The surface 36 and the recesses 38 may typically be formed in a block, panel, or plate 40. Mold 30 may include a rim or peripheral barrier 42, for example, encircling the perimeter of plate 40, and rim 42 may function to retain the curable fluid 32 introduced to mold 30. In one aspect, mold 30 may be referred to as the “A mold” in a two mold, A mold/B mold, fabrication process. Further aspects and details of mold 30 may be found and described with respect to FIGS. 1 through 8 of co-pending U.S. patent application Ser. No. 15/833,747, the disclosure of which is included by reference herein in its entirety.

After allowing the curable fluid 32 to cure (or harden), for example, for at least about 1 hour to at least about 6 hours, according to an aspect of the present invention, the cured fluid 32 may from a portion of an impact-dissipating liner.

FIG. 6 is a perspective view of an at least partially cured portion 46 of an impact-dissipating liner produced from the mold 30 shown in FIG. 5 according to one aspect of the invention. In one aspect of the invention, portion 46 comprises the cured fluid 32, for example, “the first cured fluid,” of the impact-dissipating liner as removed from mold 30. As shown in FIG. 6, portion 46 includes a sheet 48, for example, “a first flexible sheet,” comprising the cured fluid and a plurality of projections 49 from the flexible sheet 48 defined by the curable fluid cured in the plurality of recesses 38 of mold 30. (See FIG. 5.) Projections 49, and any projections disclosed herein, may comprise the shape and dimensions of recesses 38 disclosed herein, for example, right circular or non-circular cylindrical projections. As also shown in FIG. 6, portion 46 may include one or more peripheral walls or barriers 47 (shown in phantom). Walls 47 may typically be formed from cured fluid 32 solidifying in peripheral slots (not shown) in mold 30.

According to aspects of the invention, the sheet 48 of portion 46 may have a thickness ranging from about 0.5 millimeters [mm] to about 30 mm, but the thickness of sheet 48 may typically range from about 1 mm to about 5 mm. The thickness of the walls 47 may be comparable in thickness to the thickness of sheet 48.

According to aspects of the invention, portion 46 shown in FIG. 6 may comprise a first portion of at least two portions of cured fluid that may be used to fabricate an impact-dissipating liner according to aspects of the invention. In one aspect, the at least partially cured portion 46 may be referred to as the “A part” in a two mold, A part/B part, fabrication process. FIGS. 7 through 11 illustrate the fabrication of a second portion, or “B part,” of the impact-dissipating liner that can be mated with portion 46 shown in FIG. 6.

FIG. 7 is a perspective view of a mold 50 for fabricating another, or second, portion of an impact-dissipating liner shown in FIG. 1 according to an aspect of the invention. As shown in FIG. 7, in this aspect, mold 50 is adapted to receive a curable fluid 52, for example, a “second curable fluid.” Mold 50 may comprise a surface 54 formed on a block, panel, or plate 56 and projections 60 from surface 54. Mold 50 may include a rim or peripheral barrier 58, for example, encircling the perimeter of plate 56, and rim 58 may function to retain the curable fluid 52 introduced to mold 50.

As shown in FIG. 7, mold 50 may include a plurality of projections 60, for example, a plurality of cylindrical projections, for example, circular cylindrical, rectangular cylindrical, or rectangular cylindrical projections. In one aspect, mold 50 may be referred to the “B mold” in a two mold, a mold/B mold, fabrication process.

Mold 30 shown in FIG. 5 and mold 50 shown in FIG. 7, and any mold disclosed herein, may be provided in any appropriate material, for example, in wood, in plastic, or by a metal. For example, in one aspect, molds 30 and 50 may be fabricated from wood, such as, a hardwood. In other aspect, molds 30 and 50 may be made from a conventional plastic, for example, molded from a polyethylene. In another aspect, molds 30 and 50 may be formed or machined from a metal, for example, steel, a stainless steel, a tool steel, or an aluminum.

According to an aspect of the invention, a curable fluid 52, for example, a “second curable fluid,” may be introduced to surface 54 having projections 60 of mold 50 and at least partially covers surface 54 with uncured fluid 52. Curable fluid 52 is shown to be representatively poured on to mold 30 from a container 53; however, according to aspects of the invention, fluid 52 may be introduced to mold 50 by any conventional means, for example, via one or more nozzles (not shown).

FIG. 8 is a top plan view of mold 50 shown in FIG. 7 having a curable fluid 52. FIG. 9 is a cross-sectional view of mold 50 and curable fluid 52 shown in FIG. 8 as viewed along section lines 9-9 in FIG. 8.

As shown in FIG. 9, before, after, or during the introduction of curable fluid 52 to mold 50, at least some fabric 62 may typically be introduced to mold 50. If curable fluid 52 is present, fabric 62 may contact and/or be immersed in curable fluid 52. According to aspects of the invention, fabric 62 may comprise one or more fabric pieces and contact curable fluid 52 and/or at least partially contact surface 54 of mold 50. Two or more fabric pieces 62 may lay one on top of the other fabric piece, or side by side, for example, with or without overlap of fabric pieces. In one aspect, fabric 62 may be shaped to cover or engage substantially the entire exposed surface 54 of mold 50; however, in some aspects, fabric 62 may not cover the entire surface, for example, due to fabrication tolerances and/or to facilitate assembly of fabric 62 into mold 50.

As shown in FIG. 9, fabric 62 may include one or more, but typically a plurality of, perforations or holes 64 positioned and sized to engage projections 60 in mold 50. Perforations 64 may be circular when projections 60 are circular cylindrical, as shown in FIGS. 8 and 9, but perforations 64 in fabric 62 may be non-circular, for example, when projections 60 are not circular cylindrical. Accordingly, perforations 64 may be oval, triangular, square, rectangular, pentagonal, hexagonal, or any other polygonal shape.

According to aspects of the invention, fabric 62 may comprise any woven, non-woven, knitted, or non-knitted fabric or sheet material. In one aspect of the invention, structure 62 may be referred to as a “fabric,” however, it is envisioned that any form of thin material, cloth, or textile may be used for fabric 62 and provide enhancements to the liners disclosed herein. In one aspect, fabric 62 may be any form of thin material made by, for example, weaving, felting, and/or knitting, for example, of natural and/or synthetic fibers and/or filaments. In one aspect, fabric 62 may be pliable, that is, easily bent or deformed.

According to aspects of the invention, fabric 62 may have a thickness ranging from about 0.001 inches [in.] to about 0.25 in., but typically has a thickness ranging from about 0.005 in. to about 0.05 in., for example, about 0.0085 in.

In one aspect, fabric 62 may be a material made from a natural material, a plastic, an elastomer, or a metal. For example, fabric 62 may be made from cellulose fibers, for example, silk fibers, wood fibers, rayon fibers, and/or carbon fibers. In another aspect, fabric 62 may be made from metal sheets or metal fibers, for example, thin aluminum, steel, or stainless steel sheets or woven metal filaments. In one aspect, fabric 62 may be made from one or more elastomeric or rubber materials, for example, thin sheets or woven filaments of one or more of the following elastomers: a natural polymer, such as, polyisoprene rubber, or a synthetic polymer, such as, a neoprene, a thermoplastic elastomer, a thermoplastic rubber, and a polyvinyl chloride, or an ethylene propylene diene monomer (EPDM) rubber, and the like.

In one aspect, fabric 62 may be made from fiberglass, for example, chopped strand fiberglass and/or woven fiberglass. In one aspect, fabric 62 may be woven fiberglass tissue or woven fiberglass veil, as known in the art.

In one aspect, fabric 62 may be made from carbon fibers, for example, chopped strand and/or woven carbon fibers, such as, micro- and/or nano-fibers.

In one aspect, fabric 62 may be made from thin plastic sheets or film, or plastic fibers or filaments. For example, fabric 62 may be made from thin sheets or thin fabrics of one or more of the following plastics: a polyamide (PA), for example, nylon; an aramid polymer, for example, Nomex® or Kevlar® polymer; a polyethylene (PE), both a high-density polyethylene (HDPE) and a low-density polyethylene (LDPE); a polyethylene terephthalate (PET), such as Dacron® polymer; a polypropylene (PP); a polyester (PE); a polytetrafluoroethylene (PTFE); a polystyrene (PS); an acrylonitrile butadiene styrene (ABS); a polycarbonate (PC); or a polyvinylchloride (PVC); among other plastics. For example, fabric 62 may comprise a combination of a polyethylene terephthalate (PET) (such as Dacron® PET), polyester, and an aramid polymer (such as, Nomex® aramid polymer).

In one aspect, fabric 62 may be composed of fibers or filaments having a thickness, that is, denier or a denier per filament (denier/filament). For example, in one aspect fabric 62 may have denier/filament of about 40/24.

In one aspect, fabric 62 may be composed of fibers or filaments having a turn or twist per inch (TPI). For instance, in one aspect fabric 62 may have twist per inch of about 0.1 TPI to about 5.0 TPI, for example, about 0.5 TPI in the “Z twist” direction, that is, “0.5Z.”

In one aspect, fabric 62 may be treated, for example, scoured, to remove undesirable materials, for example, dirt, oil, and/or grease. In one aspect, fabric 62 may be heat set to minimize shrinkage.

In one aspect, fabric 62 may be a fabric provided by Mohawk Fabrics Company, Inc., of Amsterdam, N.Y. For example, in one aspect, fabric 62 may be made from a material marketed under the model number “SP 403,” or its equivalent.

FIG. 10 is a cross-sectional view of the liner portion 46 shown in FIG. 6 and the mold 50 shown in FIGS. 7 through 9 prior to engagement according to an aspect of the invention. FIG. 11 is a cross-sectional view of the liner portion 46 and mold 50 shown in FIG. 10 after engagement according to another aspect of the invention.

According to an aspect of the invention, after introduction of fabric 62 into mold 50, and after introduction of the curable fluid 52, and prior to at least the partial curing or hardening of curable fluid 52, the portion 46 of the impact-dissipating liner, for example, as shown in FIG. 6, may be introduced to the uncured or at least partially cured fluid 52 in mold 50 as shown in FIGS. 10 and 11 to mate the portion 46 with the uncured curable fluid 52. A representative display of fabric 62 prior to introduction into mold 50 is shown in phantom in FIG. 10 for reference.

As indicated by arrow 66 in FIG. 10, in one aspect, portion 46 may be mated with uncured portion 52, for example, uncured portion 52 may be contacted with the lower extremities or the distal ends 68 of projections 49 to at least partially contact or imbed the distal ends 68 of projections 49 into fluid 52. In one aspect, flexible sheet 46 of the first cured fluid and the plurality of projections 49 may be introduced to the second curable fluid 52 and fabric 62 where distal ends 68 of the plurality of projections 49 contact fabric 62 and the second curable fluid 52.

Once the distal ends 68 of projections 49 contact fabric 62 and/or are embedded in fluid 52, fluid 52, for example, the “second curable fluid,” may be cured or allowed to cure to form a second flexible sheet 52, that is, a second portion of the impact-dissipating liner, where the flexible sheet 52 is adhered to the distal ends 68 of the plurality of projections 49. The assembled and cured portions 46 and 52 are shown by the assembled liner 10 shown in FIG. 1.

The aspects of the invention shown and described with respect to FIGS. 1 through 11 comprise the general features of various aspects of the invention. Though the shapes of molds 30 and 50 and the resulting liner portions are shown as rectangular in shape in FIGS. 1 through 11, this rectangular shape is non-limiting and was used to facilitate the disclosure of aspects of the invention. It is envisioned that aspects of the invention are not limited to a rectangular shape, but may be practiced and provided in any convenient shape that is consistent with the desired application, for example, the desired protection of a surface from impact loading, among other things. The following disclosure and figures illustrate several more specific shapes of embodiments, again, non-limiting, of the general features and aspects disclosed in FIGS. 1 through 11.

FIG. 12 is a top plan view of another mold 70, having a curable fluid 72, for fabricating a portion of a liner according to another aspect of the invention. Though aspects of the invention may be used for protecting any appropriate surface of a structure or of human or animal, in the aspect of the invention shown in FIG. 12, mold 70 is shaped and sized to provide a liner for a headgear, for example, a helmet liner, such as, a motorcycle helmet liner. FIG. 13 is a perspective view of mold 70 and curable fluid 72 shown in FIG. 12.

As shown in FIGS. 12 an 13, according to aspects of the invention, the curable fluid 72, or a “first curable fluid,” for example, a liquid silicone rubber (LSR), is introduced to mold 70, and the curable fluid 72 is then allowed to cure, that is, solidify or harden, to form a portion of an impact-dissipating liner. As discussed herein, according to aspects of the invention, the portion of the impact-dissipating liner formed in mold 70 can then be mated with another portion of the impact-dissipating liner to fabricate a substantially complete liner, which, for example, can then be filled with a fluid, for example, a liquid.

As shown in FIGS. 12 and 13, mold 70 may include a surface 74, and surface 74 includes a plurality of projections 76 and recesses 78 surrounding projections 76 each distributed about surface 74, for example, uniformly distributed, and into which curable fluid 72 flows and substantially fills each recess 78 with curable fluid 72. In FIGS. 12 and 13, recesses 78 are located beneath fluid 72 and identified by phantom lines. As shown, projections 76 may be cylindrical, for example, circular cylindrical, and recesses 78 may be circular, though other geometric or non-circular shaped projections and recesses may be used. The number of projections 76 and recesses 78 are shown in FIGS. 12 and 13 are representative of one aspect of the invention, but aspects of the invention may have as few as 5 projections 76 and recesses 78 to tens, hundreds, or even thousands of recesses projections 76 and recesses 78, for example, depending upon the size and application of the aspect of the invention.

The surface 74 and the projections 76 and recesses 78 may typically be formed in a block, panel, or plate 80. Mold 70 may include a rim or peripheral barrier 82, for example, encircling the perimeter of plate 80, and rim 82 may act to retain the curable fluid 72 introduced to mold 70. In one aspect, mold 70 may include one or more peripheral recesses or slots 83 (beneath fluid 72 in FIGS. 12 and 13) adapted to receive curable fluid 72 in a fashion similar to recesses 78, in other aspects, recessives or slot 83 may be omitted. In one aspect, mold 70 may be referred to as the “A mold” in a two mold, A mold/B mold, fabrication process. Further aspects and details of mold 80 may be found and described with respect to FIGS. 1 through 8 of co-pending U.S. patent application Ser. No. 15/833,747, the disclosure of which is included by reference herein in its entirety.

After allowing the curable fluid 72 to cure (or harden), for example, for at least about 1 hour to at least about 6 hours, according to an aspect of the present invention, the cured fluid 72 may comprise a portion of an impact-dissipating liner.

FIG. 14 is a perspective view of a portion 84 of a liner fabricated with the mold 70 shown in FIGS. 12 and 13 according to one aspect of the invention. FIG. 15 a detailed perspective view of a portion of the portion 84 of the liner shown in FIG. 14. In one aspect of the invention, portion 84 comprising the cured fluid 72, for example, “the first cured fluid,” of the impact-dissipating liner is removed from mold 70. As shown in FIGS. 14 and 15, portion 84 includes a sheet 86, for example, “a first flexible sheet,” comprising the cured fluid and a plurality of projections 88 from the flexible sheet 86 defined by the curable fluid cured in the plurality of recesses 78 of mold 70. Projections 88, and any projections disclosed herein, may comprise the shape and dimensions of recesses 78 disclosed herein, for example, right circular or non-circular cylindrical projections. As also shown in FIGS. 14 and 15, portion 84 may include one or more peripheral walls or barriers 90. Walls 90 may typically be formed from cured fluid 72 solidifying in peripheral slots 83 of mold 70. In one aspect, portion 84 may be referred to as the “A portion” or “A part” in a two part, A part/B part, fabrication process.

Though not shown in FIGS. 12 through 15, in one aspect, one or more sheets of fabric, for example, one or more reinforcing sheets of fabric, may be introduced to sheet 86 of portion 84, for example, as shown and described below with respect to FIGS. 16 to 22. According to this aspect, the sheet of fabric in sheet 86 of portion 84 may enhance the properties of the liner having a sheet of fabric (120, see below) to provide two reinforcing sheets. In another aspect, the one or more sheets of fabric introduced to portion 86 may be the only sheets in a liner, and a second layer or sheet (120, see below) may be omitted.

FIG. 16 is a top plan view of another mold 100, having a curable fluid 102, for fabricating another portion of a liner according to another aspect of the invention. FIG. 17 is a detailed perspective view of a portion of mold 100 shown in FIG. 16. As shown in FIGS. 16 and 17, in this aspect, mold 100 is adapted to receive a curable fluid 102, for example, a “second curable fluid.” Mold 100 may comprise a surface 104 formed on a block, panel, or plate 106 and may include a rim or peripheral barrier 108, for example, encircling the perimeter of plate 106, and rim 108 may function to retain the curable fluid 102 introduced to mold 100.

As shown in FIGS. 16 and 17, mold 100 may include a plurality of projections 110, for example, a plurality of cylindrical projections, for example, circular cylindrical, rectangular cylindrical, or rectangular cylindrical projections. In one aspect, mold 100 may be referred to the “B mold” in a two mold, A mold/B mold, fabrication process.

FIG. 18 is a top plan view of mold 100 and curable fluid 102 shown in FIGS. 16 and 17 having a fabric 120 according to an aspect of the invention. FIG. 19 is a perspective view of mold 100 and curable fluid 102 shown in FIG. 18 having fabric 120 immersed or in contact with curable fluid 102 according to an aspect of the invention. Fabric 120 may be similar to and have all the attributes of fabric 62 disclosed herein. For example, fabric 120 may typically comprise one or more fabric pieces and contact curable fluid 52 and/or at least partially contact surface 104 of mold 100, and fabric 120 may be shaped to cover or engage substantially the entire exposed surface 104 of mold 100. However, in some aspects, fabric 120 may not cover the entire surface 104, for example, due to fabrication tolerances and/or to facilitate assembly of fabric 120 into mold 100.

As also shown in FIG. 18, in one aspect, fabric 120 may be colored or tinted, for example, have a distinctive color that can be an effective means of, among other things, providing an indication of the presence of fabric 120 within an impact-dissipating liner. For example, fabric 120 may have a distinctive color, such as, the bright orange color shown in FIG. 18, though other colors or combinations of colors, such as, red, green, blue, indigo, or violet, may be used for fabric 120. The colored fabric 120 may be located within an otherwise, transparent, translucent, colorless, or faintly colored liner material, such as, cured liquid silicone rubber (LSR). In one aspect, the color of fabric 120 may be reflective or visible under low or no illumination so that when the fabric containing liner is exposed, the liner can provide a warning or identification to others. In one aspect, fabric 120 may include a pattern of one or more colors, such as, an image, a logo, one or more words, or a trademark, and the like.

As shown in FIGS. 18 and 19, fabric 120 may include one or more, but typically a plurality of, perforations or holes 122 positioned and sized to engage projections 110 in mold 100. Perforations 122 may be circular when projections 110 are circular cylindrical, as shown in FIGS. 18 and 19, but perforations 122 in fabric 120 may be non-circular, for example, when projections 110 are not circular cylindrical. Accordingly, perforations 122 may be oval, triangular, square, rectangular, pentagonal, hexagonal, or any other polygonal shape.

According to aspects of the invention, fabric 120 may comprise any woven, non-woven, knitted, or non-knitted fabric or sheet material disclosed herein, and be made of any one or more of the materials and have any one of the properties and dimensions disclosed herein. For example, in one aspect, fabric 120 may be provided by Mohawk Fabrics Company, Inc., for example, fabric 120 may be made from a material marketed under the model number “SP 403” as disclosed herein, or its equivalent.

Again, as with fabric 62 disclosed herein, the structure referenced as fabric 120 may be referred to as a “fabric,” however, it is envisioned that any form of thin material, cloth, or textile may be used for fabric 120 and provide enhancements to the liners disclosed herein. In one aspect, fabric 120 may be any form of thin material made by, for example, weaving, felting, and/or knitting, for example, of natural and/or synthetic fibers and/or filaments. In one aspect, fabric 120 may be pliable, that is, easily bent or deformed.

FIGS. 20, 21, and 22 are perspective views of mold 100, curable fluid 102, and fabric 120 shown in FIGS. 18 and 19 while curable fluid 102 is being introduced according to aspects of the invention. In one aspect of the invention, curable fluid 102 may be introduced to mold 100—for example, over fabric 120—by any conventional means. However, as shown in the aspect of the invention shown in FIGS. 20, 21, and 22, curable fluid 102 may be introduced via one or more injection nozzles 130. For example, nozzle 130 may be in fluid communication with curable fluid supply (not shown) and manually or automatedly introduced to mold 120, for instance, under pressure. For example, in one aspect, nozzle 130 may be controlled by an automated controller, for instance, a controller having a program executed on a digital device, for example, a programmable logic controller (PLC) or a computer, where the position of one or more nozzles 130 and the flow of curable fluid 102 is controlled and monitored, for example, based upon user input and user feedback.

According to an aspect of the invention, after introduction of fabric 120 and uncured fluid 102 into mold 100, and prior to at least the partial curing or hardening of uncured fluid 102, the portion 84 of the impact-dissipating liner, for example, as shown in FIGS. 14 and 15, may be introduced to the uncured or at least partially cured fluid 102 in mold 100, for example, in a manner shown in FIGS. 10 and 11, to mate the portion 84 with the fluid 102.

In one aspect, portion 84 shown in FIGS. 14 and 15 may be mated with uncured portion 102, for example, uncured portion 102 may be contacted with the lower extremities or the distal ends of projections 88 of portion 84 to at least partially contact or imbed the distal ends of projections 88 into fluid 102. Once the distal ends of projections 88 contact fabric 120 and/or are embedded in fluid 102, fluid 102, for example, the “second curable fluid,” may be cured or allowed to cure to form a second flexible sheet 102, that is, a second portion 102 of the impact-dissipating liner, where the flexible sheet formed from cured fluid 102 is adhered to the distal ends of the plurality of projections 88 of portion 84. The assembled liner 140 shown in FIG. 23 shows one example of assembled and cured portions 84 and 102.

FIG. 23 is a perspective view of an impact-dissipating liner 140 produced by mating the liner portion 84 shown in FIGS. 14 and 15 with the liner portion produced by mold 100, curable fluid 102, and fabric 120 shown in FIGS. 16 through 22 according to an aspect of the present invention. Impact-dissipating liner 140 includes a flexible, fluid impermeable enclosure 141 having an upper wall 143, a lower wall 145, and a sidewall 149 between upper wall 143 and lower wall 145. According to aspects of the invention, liner 140 includes a plurality of cavities 147 extending between the upper wall 143 and the lower wall 145, each of the plurality of cavities 147 having cavity sidewalls extending from the upper wall to the lower wall. A portion of liner 140 is shown cut-away in FIG. 23 to illustrate one relative location of fabric 120 in liner 140. In one aspect of the invention, liner 140 may include at least two sheets of fabric 120, for example, one or more sheets 120 embedded in cured fluid 102 and one or more sheets embedded in the cured sheet 86 of liner portion 84.

According to aspects of the invention, as disclosed herein, liner 140 includes an internal substantially fluid-tight cavity 142, and a fluid 144 is introduced to cavity 142 to provide an impact dissipating liner. The fluid 144 may be introduced to cavity 142 by conventional means, for example, via a syringe 26, as shown in FIG. 1.

Fluid 144 may be any liquid or gas that provides the impact-dissipating characteristic desired. For example, fluid 144 may be substantially water; in another aspect, the fluid may be oil, for example, naturally occurring oil or synthetic oil. In one aspect, the fluid may include a diol, for example, ethylene glycol and/or propylene glycol. In one aspect, the fluid may be a saline solution, or its equivalent. In one aspect, fluid 144 may be a polyol, for example, a polyether polyol. In one aspect, fluid 144 may be polyether polyol provided by EverChem Specialty Chemicals of Media, Pa., for example, a polyether polyol provided by EverChem under the trade name PPG-1000 Polyol.

In another aspect, fluid 144 may be a polydimethylsiloxane fluid (also know as a “silicone fluid), for example, a polydimethylsiloxane fluid marketed by CHT USA as a QM Diluent or its equivalent; however, liquid 14 may comprise any polydimethylsiloxane fluid. As known in the art, polydimethylsiloxane comprises a group of polymeric organosilicon compounds that are commonly referred to as “silicones.” Polydimethylsiloxane may be abbreviated “PDMS’ and has the chemical formula [(CH₃)_(2SiO)]_(n). However, in other aspects, liquid 14 may be any fluid, including water, such as, distilled water.

FIG. 24 is a perspective view of another impact-dissipating liner 150 produced by mating the liner portion 84 shown in FIGS. 14 and 15 with the liner portions produced by mold 100, curable fluid 102, and fabric 120 shown in FIGS. 16 through 22 and containing a fluid within according to an aspect of the present invention. FIG. 25 is a perspective view of the liner shown in FIG. 24. FIG. 26 is a detailed perspective view of the liner shown in FIG. 25. FIG. 27 is a detailed top plan view of the liner shown in FIG. 25. Impact-dissipating liner 150 includes a flexible, fluid impermeable enclosure 151 having an upper wall 153, a lower wall 155, and a sidewall 159 between upper wall 153 and lower wall 155. According to aspects of the invention, liner 150 includes a plurality of cavities 157 extending between the upper wall 153 and the lower wall 155, each of the plurality of cavities 157 having cavity sidewalls extending from the upper wall to the lower wall.

As shown most clearly in FIG. 27, according to one aspect of the invention, fabric 120 is sized and dimensioned where fabric 120 extends substantially to the edges of liner 150, for example, to the edges of the periphery of liner 150, as indicated by reference arrow 152, and to the edges of the through holes defined by projections 88, as indicated by reference arrow 154. In one aspect, this extension of fabric 120 to edges of liner 150 may provide enhanced strength and durability to liner 150. In other aspects, the extension of fabric 150 may not extend to the edges of liner 150, for example, due to fabrication or manufacturing tolerances among other reasons, while still providing the desired strength and durability to liner 150.

FIG. 28 is a perspective view of a human head form 210 having a helmet or headgear 212, shown partially in cross section, comprising an outer helmet shell 214 and an inner fluid-filed liner 216 according to one aspect of the invention. According to aspects of the invention, the fluid-filled liner 216 may comprise a hollow structure made from an elastomeric material, for example, a liquid silicone rubber (LSR), which contains a fluid, for example, an oil, a PDMS, a diol, or any one or more of the fluids disclosed herein, and includes recesses or holes 218 and regions having reinforcement elements 220 and 222. The material of the hollow structure of liner 216 may comprise any one or more of the materials disclosed herein, for example, a medical grade LSR, such as, a silicone rubber marketed under the trademark True Skin®.

According to aspects of the inventing, the fluid in liner 216 and the recesses or holes 218 may provide an effective means of dissipating at least some of the impact forces experienced by helmet 212 to minimize the transmission of the force of impact to the head of the wearer of helmet 212. FIG. 29 is a perspective view, similar to FIG. 28, of the human head form 210 and the fluid-filed liner 216 shown in FIG. 28, with the outer helmet shell 214 removed to more clearly illustrate aspects of the invention.

According to aspects of the invention, helmet shell 214 may be any helmet shell adapted to receive and/or retain liner 216 and may have many of the features of conventional helmets or headgear, for example, retaining straps, ear holes, trim pieces, and/or shell reinforcements, which are not shown in FIG. 1/28. In one aspect helmet shell 214 may be fabricated from any appropriate material, for example, a metal, a plastic, or even a wood. However, typically, helmet shell 214 may typically be fabricated from a plastic, for example, a polycarbonate, such as, a polycarbonate shell fabricated by injection molding, or an equivalent process. In one aspect, shell 214 may be a helmet as shown in U.S. Design Pat. Des. 844,252 or U.S. Design Pat. Des. 853,038.

In one aspect, regions in the liner 216 having reinforcement elements 220 and 222 are positioned to withstand helmet impact, for example, to withstand helmet impact while dissipating the force and/or energy of the impact into the liner, and thus reducing and/or minimizing the effect of the impact upon the head of the wearer. In one aspect, the locations of regions in the liner 216 having reinforcement elements 220 and 222 are positioned to optimize the distribution of energy of the impact. In another aspect, the location of regions in the liner 216 having reinforcement elements 220 and 222 are chosen to optimize and/or enhance the structural integrity of liner 216. For example, in one aspect, the locations of reinforcement elements 220 and 222, and other reinforcement elements disclosed herein, in liner 216 are selected where it is envisioned liner 216 is most likely to receive impact loading.

As shown in FIGS. 28 and 29, according to one aspect of the invention, fluid-filed liner 216 includes one or more reinforcement elements 220 and 222 comprising at least one reinforcing material (as discussed below), for example, a material that strengthens the structural integrity of liner 216 to minimize or prevent the structural damage of liner 216 during expected loading, for example, impact loading.

According to aspects of the invention, liner 216 may be similar in design and construction or substantially identical in design and construction to the fluid-filled liners disclosed in U.S. Pat. No. 8,856,972 or in pending U.S. patent application Ser. No. 15/833,747, the disclosures of which are included by reference herein, while having the reinforcement elements disclosed herein. For example, in one aspect, liner 216 may comprise any one of the fluid-filled liners disclosed in U.S. Pat. No. 8,856,972 or in pending U.S. patent application Ser. No. 15/833,747 and having one or more reinforced areas 220, 222 as disclosed herein.

FIG. 30 is a perspective view of fluid-filled liner 216 shown in FIG. 29 when removed from head form 210 and from helmet 214, for example, as laid out on a surface. FIG. 31 is a top plan view the fluid-filled liner 216 shown in FIG. 30, and FIG. 32 is a right-side elevation view of the fluid-filled liner 216 shown in FIG. 31, the left-side elevation view being a mirror image thereof. As shown, impact-dissipating liner 216 includes a flexible, fluid impermeable enclosure 217 having an upper wall 246, a lower wall 248, and a sidewall 250 between upper wall 246 and lower wall 248. According to aspects of the invention, liner 216 includes a plurality of cavities 251 extending between the upper wall 246 and the lower wall 248, each of the plurality of cavities 251 having cavity sidewalls extending from the upper wall to the lower wall.

As shown in FIGS. 30 through 32, in one aspect liner 216 may comprise a plurality of lobes or sections 228, 230, 232, and 234 having recesses or holes 218 and extending from central portion 236 having recesses or holes 218. For example, lobes 228 and 232 may be side lobes, lobe 234 may be a rear lobe, and lobe 230 may be a front lobe of liner 216. According to aspects of the invention, lobes or sections 228, 230, 232, and 234 may be isolated or separated by recesses or cavities 238. Lobes or sections 228, 230, 232, and 234 may be shaped and positioned wherein, when liner 216 is placed in helmet shell 214, recesses or cavities 238 may be substantially eliminated wherein adjacent surfaces of lobes 228, 230, 232, and 234 may abut each other to form a substantially continuous barrier. As shown in FIG. 29, for example, the contact or abutment of sections 228, 230, 232, and 234 when liner 216 is positioned in helmet 214 may form lines of contact 240 where cavities 238 once appeared. Though in one aspect, the contact between sections 228, 230, 232, and 234 may be continuous, in other aspects, it is envisioned that some separation may be present between adjacent sections 228, 230, 232, and 234 along lines of contact 240.

As shown in FIGS. 30 and 31, according to aspects of the invention, liner 216 includes at least one, but typically, a plurality of, reinforced areas as disclosed herein, for example, having four reinforcement elements 220, 222, 224, and 226. According to one aspect, each lobe 228, 230, 232, and 234 may include one or more reinforcement element, though in FIGS. 30 through 32 each lobe 228, 230, 232, and 234 includes a single reinforcement element 220, 222, 224, and 226, respectively. In one aspect, central portion 236 of liner 216 may include one or more reinforcement elements.

FIG. 33 is a cross sectional view of a portion of the fluid-filled liner 216 shown in FIG. 31 as viewed through the section lines 33-33 shown in FIG. 31. The cross sectional view shown in FIG. 33 includes the lobe 230 of liner 216 having the reinforcement element 222 about hole 218, for example, a through hole, having a side wall 219. As shown in FIG. 33, liner 216 may typically comprise a hollow structure or enclosure 217 containing a fluid 242, such as, an oil, a PDMS, or any fluid disclosed herein, and may typically have an upper wall 246, a lower wall 248, and a sidewall 250 between upper wall 246 and lower wall 248. As shown in FIG. 33, in one aspect, reinforcement element 222 may be embedded in upper wall 246, that is, the outer wall of liner 216, for example, embedded in the material of upper wall 246, for example, an elastomeric material. However, it is envisioned that reinforcement element 222 may be positioned anywhere in upper wall 246, upon the surface of upper wall 246, and/or below the surface of upper wall 246 of liner 216. For example, as shown in FIG. 33, reinforcement element 222 may be positioned in a layer of material distinct from, for example, above, the upper wall 246 of liner 216.

According to aspects of the invention, reinforcement elements 222, and any reinforcement element or fabric disclosed herein, may comprise a sheet of fabric, for example, one or more sheets of fabric that, according to aspects of the invention, can provide enhanced strength and durability to the reinforced areas liner 216 such that liner 216 can provide enhanced protection, for example, enhanced impact resistance or energy dissipation, to a surface adjoining liner 216.

According to aspects of the invention, reinforcement element 222, and any reinforcement element or fabric disclosed herein, may comprise any woven, non-woven, knitted, or non-knitted fabric or sheet material. In one aspect of the invention, reinforcement material 222 may be referred to as a “fabric,” however, it is envisioned that any form of thin material, cloth, or textile may be used for reinforcement element 222 and provide enhancements to the liners disclosed herein. In one aspect, reinforcement element 222 may be any form of thin material made by, for example, weaving, felting, and/or knitting, for example, of natural and/or synthetic fibers and/or filaments. In one aspect, reinforcement element 222 may be pliable, that is, easily bent or deformed.

According to aspects of the invention, reinforcement element 222, and any reinforcement element or fabric disclosed herein, may have a thickness ranging from about 0.001 inches [in.] to about 0.25 in., but typically has a thickness ranging from about 0.005 in. to about 0.050 in., for example, from about 0.010 inches to about 0.020 inches.

In one aspect, reinforcement element 222, and any reinforcement element or fabric disclosed herein, may be a material made from a natural material, a plastic, an elastomer, or a metal. For example, reinforcement element 222 may be made from cellulose fibers, for example, silk fibers, wood fibers, rayon fibers, and/or carbon fibers. In another aspect, reinforcement element 222 may be made from metal sheets or metal fibers, for example, thin aluminum, steel, or stainless steel sheets or woven metal filaments. In one aspect, reinforcement element 222 may be made from one or more elastomeric or rubber materials, for example, thin sheets or woven filaments of one or more of the following elastomers: a natural polymer, such as, polyisoprene rubber, or a synthetic polymer, such as, a neoprene, a thermoplastic elastomer, a thermoplastic rubber, and a polyvinyl chloride, or an ethylene propylene diene monomer (EPDM) rubber, and the like.

In one aspect, reinforcement element 222, or any reinforcement element or fabric disclosed herein, may be made from fiberglass, for example, chopped strand fiberglass and/or woven fiberglass. In one aspect, reinforcement element 222 may be woven fiberglass tissue or woven fiberglass veil, as known in the art.

In one aspect, reinforcement element 222, or any reinforcement element or fabric disclosed herein, may be made from carbon fibers, for example, chopped strand and/or woven carbon fibers, such as, micro- and/or nanofibers.

In one aspect, reinforcement element 222, and any reinforcement element or fabric disclosed herein, may be made from thin plastic sheets or film, or plastic fibers or filaments. For example, reinforcement element 222 may be made from thin sheets or thin fabrics of one or more of the following plastics: a polyamide (PA), for example, nylon; an aramid polymer, for example, Nomex® or Kevlar® polymer; a polyethylene (PE), both a high-density polyethylene (HDPE) and a low-density polyethylene (LDPE); a polyethylene terephthalate (PET), such as Dacron® polymer; a polypropylene (PP); a polyester (PE); a polytetrafluoroethylene (PTFE); a polystyrene (PS); an acrylonitrile butadiene styrene (ABS); a polycarbonate (PC); or a polyvinylchloride (PVC); among other plastics. For example, reinforcement element 222 may comprise a combination of a polyethylene terephthalate (PET) (such as Dacron® PET), polyester, and an aramid polymer (such as, Nomex® aramid polymer).

In one aspect, reinforcement element 222, and any reinforcement element or fabric disclosed herein, may be composed of fibers or filaments having a thickness, that is, denier or a denier per filament (denier/filament). For example, in one aspect reinforcement material 244 may have denier/filament of about 40/24.

In one aspect, reinforcement element 222 reinforcement element 222, and any reinforcement element or fabric disclosed herein, may be composed of fibers or filaments having a turn or twist per inch (TPI). For instance, in one aspect reinforcement element 222 may have twist per inch of about 0.1 TPI to about 50.0 TPI, for example, about 0.5 TPI in the “Z twist” direction, that is, “0.5Z.”

In one aspect, reinforcement element 222, and any reinforcement element or fabric disclosed herein, may be treated, for example, scoured, to remove undesirable materials, for example, dirt, oil, and/or grease. In one aspect, reinforcement element 222 may be heat set to minimize shrinkage.

In one aspect, reinforcement element 222, and any reinforcement element or fabric disclosed herein, may be a fabric provided by Mohawk Fabrics Company, Inc., of Amsterdam, N.Y. For example, in one aspect, reinforcement element 222 may be made from a material marketed under the model number “SP 403,” or its equivalent.

FIG. 34 is a top perspective view of a mold 260 that can be used to fabricate a portion of a fluid-filled liner 216 having reinforcement elements 222 according to one aspect of the invention. Mold 260 may comprise a “B Mold” used to form a portion of a liner according to an aspect of the invention, which may be mated with a portion of the liner fabricated with an “A Mold,” for example, as disclosed in FIGS. 5 through 11 and in related pending U.S. Provisional Patent Application 62/742,869, the disclosure of which is included by reference herein in its entirety.

As shown in FIG. 34, in this aspect, mold 260 is adapted to receive a curable or hardenable fluid (not shown), for example, a liquid silicone rubber (LSR). Mold 260 may comprise a surface 264 formed on a block, panel, or plate 266 and may include a rim or peripheral barrier 268, for example, encircling the perimeter of plate 266, and rim 268 may function to retain the curable fluid introduced to mold 260.

As shown in FIG. 34, mold 260 may include a plurality of projections 270, for example, a plurality of cylindrical projections, for instance, circular cylindrical, rectangular cylindrical, or rectangular cylindrical projections. As also shown in FIG. 34, mold 260 may typically take the form of the desired shape of the liner, for example, having lobes or sections 272, 274, 276, and 278 corresponding to lobes 228, 230, 232, and 234 of liner 216.

According to aspects of the invention, mold 260 typically includes at least one, but typically, a plurality of recesses or depressions 280, 282, 284, and 286 positioned and shaped to receive the desired reinforcement elements, for example, a reinforcing fabric. FIG. 35 is a top view of a detail of the mold 260 shown in FIG. 34 as identified by Detail 35 in FIG. 34.

As shown in FIGS. 34 and 35, recesses 280, 282, 284, and 286 may assume a broad range of geometric shapes, for example, depending upon the use, application, shape, and/or dimensions of the liner and the location and dimensions of projections 270 for the holes in the liner, for example, holes 218 shown in FIGS. 28 through 33. According to aspects of the invention, recesses 280, 282, 284, and 286 may have a depth below the surface 264 of between 0.01 inches to 2 inches, for example, depending upon the size and shape of the liner being formed, but typically may have a depth below the surface 264 of between 0.010 inches to 0.25 inches, for example, about 0.125 inches.

FIG. 36 is a top plan view of reinforcement elements 288, 290, 292, and 294 that may be used with mold 260 shown in FIGS. 34 and 35 to form aspects of the invention. According to aspects of the invention, the shape or outlines of reinforcement elements 288, 290, 292, and 29 may take any appropriate shape warranted, for example, by the shape of the recesses 280, 282, 284, and 286 shown in FIG. 35. As shown in FIG. 36, reinforcement elements 288, 290, 292, and 294 are fashioned in shapes that can be received by recesses 280, 282, 284, and 286 shown in FIG. 35, including, for example, having perforations or holes adapted to receive projections 270. Reinforcement elements 288, 290, 292, and 294 may be made from any one or more the materials disclosed herein, for example, from a fabric provided by Mohawk Fabrics Company, and may have a thickness as disclosed herein, for example, having denier/filament of about 40/24.

The size or outer dimensions of reinforcement elements 288, 290, 292, and 294 may vary depending upon the size and shape of the liner and helmet into which that they will be used. For example, in one aspect, reinforcement elements 288, 290, 292, and 294 may have an outer dimension or width ranging from 0.25 inches to 12 inches, but typically may have an outer dimension or width of between 2 inches to 6 inches.

FIG. 37 is of a top view of one reinforcement element 292 shown in FIG. 36. As is typical of reinforcement elements 288, 290, 292, and 294, the shape, for example, outer contour of, reinforcement element 292 is adapted to be received by recess 286 shown in FIGS. 34 and 35, and a perforation or hole 296 sized and positioned to be received by projection 270 within recess 286. For example, reinforcement element 292 may include curvilinear projections or lobes 298 and curvilinear recesses 300 shaped and positioned to be received by the curvilinear lobes and recesses of recess 286 in FIGS. 34 and 35.

FIG. 38 is a top perspective view of the mold 260 shown in FIG. 34 having its recesses 280, 282, 284, and 286 at least partially filled with a curable fluid 302, such as, a liquid silicone rubber (LSR), according to one aspect of the invention. As shown, in one aspect, curable fluid 302 may be introduced to mold 260 by one or more nozzles 304, though other conventional means may be used. As shown in FIG. 38, in one aspect, at least some curable fluid 302 may be introduced to recesses 280, 282, 284, and 286 of the mold 260 in preparation for placement of the reinforcement elements 288, 290, 292, and 294 into recesses 280, 282, 284, and 286. In one aspect, reinforcement elements 288, 290, 292, and 294 may be introduced into recesses 280, 282, 284, and 286 prior to the introduction of the curable fluid 302.

FIG. 39 is a top perspective view of mold 260 shown in FIG. 38 having its recesses 280, 282, 284, and 286 at least partially filled with a curable fluid 302 and having two reinforcement elements 292 and 294 shown in FIG. 36 according to one aspect of the invention. In one aspect, reinforcement elements 292 and 294 may be positioned manually or by an automated manipulator. As shown in FIG. 39, according to one aspect, reinforcement elements 292 and 294 may be immersed in the previously supplied curable fluid 302 and/or additional curable fluid 302 may be provided after placement of reinforcement elements 292 and 294, for example, to ensure that the curable fluid 302 substantially covers the reinforcement elements 292 and 294. In a similar fashion, reinforcement elements 288 and 290 may be positioned in recesses 280 and 284, respectively, of mold 260 prior to or after the introducing of curable fluid 302 to recesses 280 and 284.

According to aspect of the invention, after the placement of reinforcement elements 288, 290, 292, and 294 with curable material 302, further curable fluid 302 may be introduced to mold 260, a “B mold,” and then mold 260 with cured and/or uncured fluid 302 may be mated with a comparable part, for example, an “A part” fabricated from an “A mold,” to form a liner according to aspects of the invention. For example, in one aspect, this mating of an A part with a B part to form a liner is shown and discredited with respect to FIGS. 5 through 22. After appropriate hardening or curing of the curable fluid 302, and the creation of a liner having an internal cavity, the internal cavity may be substantially filled with a fluid, for example, by fluid injection, to substantially form a fluid-filed liner according to aspects of the invention.

FIG. 40 is a top plan view of a liner 310 having reinforcement elements 288, 290, 292, and 294 comprising a cured curable fluid 315 formed by hardening or curing of the curable fluid 302 and removal from B mold 260 shown in FIGS. 38 and 39 and a corresponding A part made with an A mold according to one aspect of the invention. As shown, impact-dissipating liner 310 includes a flexible, fluid impermeable enclosure 311 having an upper wall 313, a lower wall 315, and a sidewall 317 between upper wall 313 and lower wall 315. According to aspects of the invention, liner 310 includes a plurality of cavities 319 extending between the upper wall 313 and the lower wall 315, each of the plurality of cavities 319 having cavity sidewalls extending from the upper wall to the lower wall.

FIG. 41 is a perspective view of a portion of the liner 310 shown in FIG. 40 showing a detail of a reinforced region having a reinforcement material 294 embedded in cured curable fluid 315 according to one aspect of the invention.

FIG. 42 is a top plan view of a fluid-filled liner 320 having reinforcement elements 288, 290, 292, and 294 fabricated from liner 310 shown in FIG. 40 after introducing of a fluid, for example, by injection, into the cavity within liner 310.

FIG. 43 is a bottom view of a helmet assembly 330 comprising a helmet shell 335 having the fluid-filled liner 320 shown in FIG. 42 having reinforcement elements 288, 290, 292, and 294 according to one aspect of the invention.

FIG. 43 also illustrates bodies 340 and 345 that may be mounted to the inner surface of helmet shell 335 according to one aspect of the invention. In one aspect, for example, as disclosed in pending U.S. patent application Ser. No. 15/833,747, bodies 340 and bodies 345 may provide at least some retention of liner 320 in helmet 335. Bodies 340, for example, circular cylindrical bodies, may engage holes 218 in fluid-filled liner 320, for example, holes 218 within the reinforcement elements 288, 290, 292, and 294, to provide at least some retention of liner 320 in helmet 335. Bodies 345 may be polyhedral or polygonal cylindrical bodies and may engage a peripheral surface of fluid-filled liner 320 to provide at least some retention of liner 320 in helmet 335. Bodies 340 and 345 may be compressible bodies, for example, made of a plastic foam.

According to aspects of the invention, the enclosures of the liners and liner portions disclosed herein, for example, liners 10, 140, 150, 216, 310, and 320, may comprise a liquid silicone rubber, for example, a cured liquid silicone rubber, such as, a platinum-cured LSR. In one aspect, the enclosures of the liners disclosed herein may comprise a LSR marketed under the trademark True Skin®; however, the enclosures of the liners disclosed herein may comprise any cured liquid silicone rubber (LSR). In one aspect, the cured liquid silicone rubber may be a “medical grade” LSR, as known in the art, for example, an LSR having an elasticity, a viscosity, a “feel,” and/or anti-microbial properties, among other things, that are desirable in aspects of the invention.

However, in one aspect, a liquid silicone rubber marketed under the trademark True Skin® may be preferred. In one aspect, the enclosures disclosed herein may be made from CHT's True Skin® 10 having a 10 Shore A hardness (or durometer) as disclosed in CHT “Technical Data Sheet” for True Skin®10 [Rev-1, Aug. 16, 2017], which is included by reference herein. In one aspect, the enclosures disclosed herein may be made from CHT's True Skin® 20 having a 20 Shore A hardness (or durometer) as disclosed in CHT “Technical Data Sheet” for True Skin® 20 [Rev-1, Aug. 16, 2017], which is included by reference herein. In one aspect, the enclosures disclosed herein may be made from CHT's True Skin® 30 having a 30 Shore A hardness (or durometer) as disclosed in CHT “Technical Data Sheet” for True Skin® 30 [Rev-1, Aug. 16, 2017], which is included by reference herein.

As known in the art, any one of the enclosures and liners disclosed herein may be fabricated from a liquid silicon rubber produced when combining two or more components, for example, a CHT True Skin liquid silicone rubber “A” and a CHT True Skin liquid silicone rubber “B” to produce the desired liquid silicone rubber when cured.

It is also envisioned that aspects of the invention may be made from other liquid silicone rubbers, for example, a LSR marketed under the trademark SILBIONE® by Elkem Silicones of Lyon, France, or its equivalent. For example, in one aspect, one or more of the LSRs identified in Elkem's “Silbione® Liquid Silicone Rubber (LSR) Elastomers” line card dated June 2018, which is included by reference herein, may be used for an aspect of the invention.

In another aspect, the enclosures of the invention may be made from a LSR marketed by Dow Corning, or their equivalent.

In another aspect, enclosures of any one of the liners disclosed herein may be made from a LSR marketed under the trademark DRAGON SKIN™ by Smooth-On, Inc., or their equivalent. For example, one or more of the LSRs identified in Smooth-On's Technical Bulletin “Dragon Skin™ Series,” having reference number 041619-JR, which is included by reference herein, may be used for an aspect of the invention.

According to aspects of the invention, the fluid (for example, a liquid) encased in the enclosures of the liners disclosed herein, for example, liners 10, 140, 150, 216, 310, and 320, may comprise a polydimethylsiloxane fluid, for example, a polydimethylsiloxane fluid marketed as a QM Diluent by CHT, or their equivalents; however, the fluid may comprise any polydimethylsiloxane fluid. However, in one aspect, the polydimethylsiloxane fluid marketed under the trademark QM Diluent may be preferred. In one aspect, the fluid encased in the enclosures of the liners disclosed herein may comprise QM Diluent 50 having a viscosity of about 50 centipoise (cps) as disclosed in CHT “Technical Data Sheet” for QM Diluent 50 [Rev-3, Aug. 7, 2017], which is included by reference herein. In one aspect, the fluid encased in the enclosures of the liners disclosed herein may comprise QM Diluent 100 having a viscosity of about 100 cps as disclosed in CHT “Technical Data Sheet” for QM Diluent 100 [Rev-3, Aug. 7, 2017], which is included by reference herein. In one aspect, the fluid encased in the enclosures of the liners disclosed herein may comprise QM Diluent 1000 having a viscosity of about 1000 cps as disclosed in CHT “Technical Data Sheet” for QM Diluent 1000 [Rev-3, Aug. 7, 2017], which is included by reference herein. In one aspect, the fluid encased in the enclosures of the liners disclosed herein may comprise QM Diluent 5000 having a viscosity of about 5000 cps, for which a “Technical Data Sheet” has not been identified. It is envisioned that fluids of higher viscosity, for example, QM Diluents having a viscosity greater than 5000 cps may be used in aspects of the invention.

It is envisioned that fluids having other viscosities, for example, QM Diluents provided by CHT, may also be used, for example, by appropriately combining at least two fluids of known viscosity, as known in the art. Accordingly, in one aspect, polydimethylsiloxane fluids of different viscosities, such as, a CHT QM Diluents, can be mixed or otherwise combined to provide a fluid having a viscosity of at least 50 cps that can be used as a fluid in an aspect of the invention. Similarly, in one aspect, polydimethylsiloxane fluids of different viscosities, such as, a CHT QM Diluents, can be mixed or otherwise combined to provide a fluid having a viscosity of at least 100 cps that can be used as a fluid in an aspect of the invention. In one aspect, polydimethylsiloxane fluids of different viscosities, such as, a CHT QM Diluents, can be mixed or otherwise combined to provide a fluid having a viscosity of at least 500 cps that can be used as a fluid in an aspect of the invention. In one aspect, polydimethylsiloxane fluids of different viscosities, such as, a CHT QM Diluents, can be mixed or otherwise combined to provide a fluid having a viscosity of at least 1000 cps, or at least 2000 cps, or at least 3000 cps, or at least 4000 cps, or at least 5000 cps, or at least 6000 cps, or at least 8000 cps that can be used as a fluid in an aspect of the invention.

Aspects of the present invention provide versatile impact-dissipating liners for bodily and structural protection. For example, when applied to head protection, aspects of the invention can provide head protection at both low-energy and high-energy impacts, from any direction, and at any one point in time. Moreover, unlike prior art head protection, aspects of the present invention have been tested and confirmed to provide repeatable impact protection, for example, protection from multiple impacts. In addition to the energy absorbing function of aspects of the invention, the lower-profile nature of aspects of the invention compared to the prior art can provide the benefit of reducing the transmission of rotational or torsional loading on the head, neck, and/or spine by providing a lower “lever arm” to any loading. For example, where the prior art is characterized by head protection having thicker liners, for instance, 2 to 3 inches thick, aspects of the present invention can be adapted to provide a liner thickness of only about ½ inch in thickness. As known in the art, this reduction in thickness, and thus reduction of impact torsional lever arm, can dramatically reduce the torsional loading upon the head, neck, and/or spine of the user.

It will be apparent from the foregoing that the invention, in its many aspects, provides impact-dissipating liners, method of fabricating impact-dissipating liners, helmets and headgear having impact-dissipating liners, arrangements, liners, and methods for protecting heads and other bodily structures, or other general non-bodily structures for which protection is desired. Again, though aspects of the invention were shown and described with respect to a headgear and helmets, it is envisioned that aspects of the invention may used for any barrier, structure, or any impact-dissipating liner disclosed herein. In one aspect, a barrier for a motor sport may comprise one or more of the impact-dissipating liners disclosed herein, for example, a barrier or wall of a race track (for example, a motor vehicle race track) or a race course (for example, a motocross course), and the like.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “including,” and/or “having” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiment was chosen and described in order to best explain the principles of the disclosure and the practical applications, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

This written description uses examples to disclose the invention, including the best mode envisioned, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

1. An impact dissipating helmet liner comprising: a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and a sidewall extending between the upper wall and the lower wall; a fluid contained in the enclosure; and a fabric sheet positioned in at least one of the upper wall and the lower wall.
 2. The impact dissipating helmet liner as recited in claim 1, wherein the liner further comprises a plurality of cavities between the upper wall and the lower wall, each of the plurality of cavities having a cavity sidewall extending from the upper wall to the lower wall.
 3. The impact dissipating helmet liner as recited in claim 1, wherein the fabric sheet comprises one of a woven fabric, an unwoven fabric, and a knitted fabric.
 4. The impact dissipating helmet liner as recited in claim 3, wherein the fabric sheet comprises a knitted fabric comprising one of a polyethylene terephthalate (PET), a polyester, and an aramid polymer.
 5. The impact dissipating helmet liner as recited claim 1, wherein the flexible, fluid impermeable enclosure comprises a central portion and a plurality of lobes extending from the central portion, and wherein the central portion and the plurality of lobes are adapted to conform to the shape of an internal surface of a helmet.
 6. The impact dissipating helmet liner as recited in claim 5, wherein the plurality of lobes define radially extending cavities between adjacent lobes.
 7. The impact dissipating helmet liner as recited in claim 1, wherein the flexible, fluid impermeable enclosure comprises a liquid silicone rubber.
 8. The impact dissipating helmet liner as recited in claim 1, wherein the fluid comprises a liquid.
 9. The impact dissipating helmet liner as recited in claim 8, wherein the liquid comprises one of liquid silicone rubber, a polydimethylsiloxane, and a polyol.
 10. The impact dissipating helmet liner as recited in claim 1, wherein the helmet liner comprises a liner for at least one of a baseball catcher's helmet, a baseball batter's helmet, a soft ball catcher's helmet, a softball batter's helmet, a hockey helmet, a hockey goalie mask, a motorcycle helmet, a motor cross helmet, a skiing helmet, a snowboarding helmet, a skateboarding helmet, a lacrosse helmet, a bicycle helmet, a jockey helmet, an official's helmet, a medical protection helmet, a rock or ice climbing helmet, a mountain climbing helmet, a football helmet, a construction helmet, and a military helmet.
 11. A helmet having the impact dissipating helmet liner as recited in claim
 1. 12. The helmet as recited in claim 11, wherein the helmet comprises a helmet shell containing the impact dissipating helmet liner.
 13. An impact dissipating liner comprising: a flexible, fluid impermeable enclosure having an upper wall, an opposing lower wall, and a sidewall extending between the upper wall and the lower wall; a fabric sheet positioned in at least one of the upper wall and the lower wall; and a fluid contained in the enclosure.
 14. The impact dissipating liner as recited in claim 13, wherein the liner further comprises a plurality of cavities extending between the upper wall and the lower wall, each of the plurality of cavities having a cavity sidewall extending from the upper wall to the lower wall.
 15. The impact dissipating liner as recited in claim 13, wherein the fabric sheet comprises one of a woven fabric, an unwoven fabric, and a knitted fabric.
 16. The impact dissipating liner as recited in claim 15, wherein the fabric sheet comprises a knitted fabric comprising a polyethylene terephthalate (PET), a polyester, and an aramid polymer.
 17. The impact dissipating liner as recited in claim 13, wherein the flexible, fluid impermeable enclosure comprises a liquid silicone rubber.
 18. The impact dissipating liner as recited in claim 13, wherein the fluid comprises a liquid.
 19. The impact dissipating liner as recited in claim 18, wherein the liquid comprises one of liquid silicone rubber, a polydimethylsiloxane, and a polyol.
 20. The impact dissipating liner as recited in claim 13, wherein liner comprises one of a helmet liner, a head gear liner, a body armor liner, a body padding liner, a barrier liner, a wall liner, and a surface liner 21-42. (canceled) 